Read the safety rules for metalworklisted in the Metalwork merit badge pamphlet.
Describe to your counselorDiscuss how to be safe while working with metal.
Because this merit badge offers four options, show
your counselor which additional safety rules apply to the discipline
you choose and discuss them with your counselor.Discuss with your counselor the additional safety
rules that apply to the metalwork option you choose for requirement
5.

Define the term native metal.
b. Define the term malleable.
c. Define the term metallurgy.
d. Define the term alloy.
e. Name two nonferrous alloys used by pre-Iron Age
metalworkers. Name, and
name the metals that are combined to form these alloys.

f. Explain the term ferrous, and name
Name three ferrous alloys used by modern metalworkers.

g. Describe how to work–harden
a metal.

h. Describe how to anneal a
non-ferrous and a ferrous metal.

Do the following:

Work-harden a piece of 26- or 28-gauge sheet
brass or sheet copper. Put a 45-degree bend in
a small piece of 26- or 28-gauge sheet brass or
sheet copperthe metal, then heavily peen
the area along the bend line to work-harden it. Note the
amount of effort that is required to overcome the yield point in
this unworked piece of metal.

Work-harden another piece of the same sheet
brass or sheet copper. and then put a 45-degree bend in it. Note
the amount of effort that is required to overcome the yield point.
c. Soften the same bent, work hardened
piece from requirement 3a by annealing
it and then try to remove the 45–degree bend. Note the amount of
effort that is required to overcome the yield point.

Make a temper color index from a flat piece
of steel. Using hand tools, make and temper a center punch of medium-carbon
or high-carbon steel.d. Join two small pieces of scrap metal using
a hammered rivet. Repeat the process using a pop rivet.
e. Using a flatlock seam, join two pieces of scrap metal together
with either lead-free solder or silver solder.
f. Make a temper color index from a flat piece of steel. Using hand
tools, make and temper a center punch of medium-carbon or high-carbon
steel.
g. Using metal cans, practice using the basic metalworking tools
and techniques by making at least two tasteful objects that require
cutting, bending, and edging.

Find out about three career opportunities in metalworking.
Pick one and find out the education, training, and experience required
for this profession. Discuss this with your counselor, and explain why
this profession might interest you.Do ONE of the following:

Visit an experienced sheet metal mechanic, tinsmith, coppersmith,
jeweler, founder or a blacksmith at his or her workshop. You may
select a skilled hobbyist or a professional. Ask permission to see
the tools used and to examine examples of the work made at the shop.
Inquire about the level of education required to become an apprentice
craftsman.

If you have (or your counselor has) access to the internet,
explore metalworking occupations by conducting a Web search. With
your counselor’s help and guidance, find at least five metalworking–related
Web sites. Print a copy of the web pages and discuss them with your
counselor.

After completing the first four requirements, complete at least
ONE of the options listed below.

Option 1 – Sheet Metal Mechanic / Tinsmith

Name and describe the use of the basic sheet metalworking
tools.

Create a reasonably accurate sketch
of two tasteful objects to make from
sheet metal. Include each component's dimensions on your sketch,
which need not be to scale.

Make two objects out of 24- or 26–gauge
sheet metal. UseUsing patterns
either provided either
by your counselor or made by you and approved
by your counselor. Construct these objects using a metal that
is appropriate to the object's ultimate purpose, and using cutting,
bending, edging, and either soldering or brazing., make at least two tasteful objects out of
24- or 26–gauge sheet metal. Use a metal that is appropriate
to the object’s ultimate purpose.

Both objects must be constructed using
culling, bending, edging, and either soldering or brazing
b. One object also must
include at least one riveted component

c. If you do not make your
objects from zinc-plated sheet steel or tin-plated sheet
steel, preserve your work from oxidation.

Option 2 - Silversmith

Name and describe the use of a silversmith'sthe basic tools used
by a silversmith.

Create a reasonably accurate hand-drawn
sketch of two tasteful objects to make
from sheet silver. Include each component's dimensions on your
sketch, which need not be to scale.

Make two objects out of 8- or 20- gauge
sheet copper. Use Using patterns
either provided either
by your counselor or made by you and approved
by your counselor. Both objects must include a soldered joint.,
make at least two tasteful objects out of 18- or 20–gauge sheet
Copper. If you have prior silversmithing experience,
you may substitute sterling silver, nickel silver, or lead free
pewter.

At least one object must include a sawed component you
have made yourself.

At least one object must include a sunken part you have
made yourself.c. Both objects must include a soldered
joint.

d. Clean and polish your objects.

Option 3 – Founder

Name and describe the use of the basic parts of a two–piece
mold. Name at least three different types of molds.

Create a reasonably accurate sketch
of two tasteful objects to cast in
metal. Include the height, width, and length
on the sketch.Include each component's
dimensions on your sketch, which need not be to scale.

Do the following:
a. UsingMake two molds, one using
a pattern provided by your counselor and another
one made by yourself, make two molds.you have made yourself that has been approved
by your counselor. Position the pouring gate and vents
yourself. Do not use copyrighted materials as patterns.

b. MakeUsing
lead-free pewter, make a casting using a mold provided
by your counselor and make a casting using
the mold you have made. Use lead free pewter when casting
each mold.

c. Remove all evidence of gates, vents,
and parting-line flash from your castings.Using lead-free pewter, make a casting
using the mold that you have made.

Option 4 - Blacksmith

Name and describetell the use of a
blacksmith'sthe basic tools
used by a blacksmith.

Make a reasonably accurate sketch
of two tasteful objects to hot-forge.
Include each component’s dimensions on your sketch,
which need not be to scale.

Using low–carbon steel at least ¼ inch thick, perform the
following exercises:

Draw out by forging a taper.

Use the horn of the anvil by forging a U-shaped bend.

FormTwist
steel by placing a decorative twist in a piece of
square steel.

Use the edge of the anvil to bend metal by forging an
L–shaped bend.

Using low-carbon steel at least ¼ inch thick, make
theat least
two tasteful objects
you sketched that require hot-forging.
Be sure you have your counselor's approval
before you begin.

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